Low-pressure casting furnace system

ABSTRACT

A casting system is provided with at least two low-pressure casting furnaces. Each of the at least two low-pressure casting furnaces is adapted to be connected in fluid communication with a mold. At least one controller is in cooperation with the at least two low-pressure casting furnaces to collectively operate the low-pressure casting furnaces to cast a material into the mold.

TECHNICAL FIELD

Various embodiments relate to low-pressure casting furnace systems.

BACKGROUND

Low-pressure sand casting has been utilized to cast aluminum components.

SUMMARY

According to an embodiment, a casting system is provided with at least two low-pressure casting furnaces. Each of the at least two low-pressure casting furnaces is adapted to be connected in fluid communication with a mold. At least one controller is in cooperation with the at least two low-pressure casting furnaces to collectively operate the low-pressure casting furnaces to cast a material into the mold.

According to a further embodiment, a plurality of stalk tubes is each provided upon one of the at least two low-pressure casting furnaces to provide fluid communication from the one of the at least two low-pressure casting furnaces to the mold.

According to an even further embodiment, only one stalk tube is provided for each of the at least two low-pressure casting furnaces.

According to another further embodiment, a frame is provided. Each of the at least two low-pressure casting furnaces is supported upon the frame.

According to an even further embodiment, a plurality of leveling devices is supported upon the frame. Each of the at least two low-pressure casting furnaces is supported upon one of the plurality of leveling devices.

According to an even further embodiment, the mold is supported upon the frame above the at least two low-pressure casting furnaces in fluid cooperation with each of the at least two low-pressure casting furnaces.

According to another further embodiment, the at least two low-pressure casting furnaces are further provided as at least three low-pressure casting furnaces. One pair of the at least three low-pressure casting furnaces is spaced apart a greater distance than another pair of the at least three low-pressure casting furnaces.

According to another further embodiment, the at least two low-pressure casting furnaces are further provided as at least three low-pressure casting furnaces that are arranged in a shape of a triangle with a center of each low-pressure casting furnaces at a vertex of the triangle.

According to an even further embodiment, the shape of the triangle is a right triangle.

According to an even further embodiment, two sides of the triangle that are opposite and adjacent to an acute angle of the triangle are different lengths.

According to another further embodiment, the mold is oriented upon the at least two low-pressure casting furnaces in fluid cooperation with each of the at least two low-pressure casting furnaces.

According to an even further embodiment, the mold is further provided as a sand mold.

According to another embodiment, a casting system is provided with a frame. A plurality of leveling devices is supported upon the frame. A plurality of low-pressure casting furnaces is each supported upon one of the plurality of leveling devices, each adapted to be connected in fluid communication with a mold.

According to another embodiment, a method for low-pressure casting provides two low-pressure casting furnaces in an adjacent series. A mold is provided upon the low-pressure casting furnaces in fluid communication with each of the two low-pressure casting furnaces. A single component is cast in the mold from the two low-pressure casting furnaces.

According to a further embodiment, the two low-pressure casting furnaces are leveled.

According to another further embodiment, the component is cast from an aluminum material.

According to another embodiment, a component is low-pressure cast from a method providing two low-pressure casting furnaces in an adjacent series. A mold is provided upon the low-pressure casting furnaces in fluid communication with each of the two low-pressure casting furnaces. A single component is cast in the mold from the two low-pressure casting furnaces.

According to another further embodiment, the component weighs up to three thousand pounds.

According to another further embodiment, the component occupies a volume of up to one thousand, one hundred and fifty-two cubic feet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a casting system, according to an embodiment, illustrated with three low-pressure sand-casting furnaces;

FIG. 2 is a side perspective view of one of the low-pressure sand-casting furnaces of FIG. 1;

FIG. 3 is a side section view of the low-pressure sand-casting furnace of FIG. 2; and

FIG. 4 is another front perspective view of the casting system of FIG. 1, illustrated installed into a manufacturing environment.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

FIG. 1 illustrates a casting system 20 according to an embodiment. The casting system 20 includes a plurality of furnaces 22 to melt a material, such as aluminum. The furnaces 22 are low pressure furnaces and are controlled to inject the molten aluminum into a mold 24 to cast a metal component. The mold 24 is a sand mold 24 oriented above the furnaces 22. According to an embodiment, the mold 24 is supported directly upon the furnaces 22. The mold 24 is cooled to cool and harden the metal component. Then, the component is removed from the mold 24. This casting method is referred to as a low-pressure sand-casting (LPSC) method.

FIGS. 2 and 3 illustrate one of the furnaces 22 in greater detail. The furnace 22 is illustrated with a sand mold 28. The furnace 22 includes a sealed pressure vessel 30. Referring now to FIG. 3, the vessel 30 contains a ceramic crucible 32 and a heater 34 to melt aluminum 36. Nitrogen gas is utilized to apply pressure (such as one bar) to a surface of the molten aluminum 36 forcing it up a ceramic stalk tube 38 and into the sand mold 28. The heater may be located anywhere within, or external to, the furnace 22. Utilization of such a low pressure eliminates the utilization of a press to withstand high pressures. According to another embodiment, a mechanical pump is employed to inject the aluminum into the sand mold 28.

A cover 40 is provided on the vessel 30 to seal the vessel. A platen 42 is provided on the cover 40. The mold 28 is installed upon the platen 42 in fluid communication with the stalk tube 38. The stalk tube 38 extends through the cover 40 and the platen 42 to deliver the molten metal 36 to the mold 28.

Referring again to FIG. 1, the casting system 20 includes a controller 46 in electrical and pressure communication with each of the furnaces 22. Although one controller 46 is depicted, any number of controllers 46 may be employed. For example, a plurality of controllers 46 may be employed, which may be independently controlled to start simultaneously. A plurality of valves is provided at the controller 46 in fluid communication with the furnaces 22. Referring again to FIG. 3, the controller 46 operates the valve to regulate the filling of Nitrogen into the furnaces 22, and consequently aluminum into the mold 28. The valves are also controlled to apply pressure to a column 48 of molten aluminum 36 as the casting solidifies inside the sand mold 28. By these low-pressure sand-casting methods, superior metal quality is obtained in the cast component, also referred to as a casting. Although the sand mold 28 is illustrated, a steel tool mold may be employed.

Some foundries utilize multiple stalk tubes within one large crucible to feed aluminum into multiple castings at the same time or to feed aluminum into different regions of one larger casting. The casting system 20 includes multiple furnaces 22 to regulate pressure of cast material into a large mold.

The casting system 20 includes a frame 50, which may be formed as a steel weldment to support the casting system 20 upon an underlying support surface, such as a concrete floor 52. The frame 50 may occupy an area of approximately fifteen feet by fifteen feet. Leveling mechanisms 54 are provided upon the frame 50. One furnace 22 is provided upon each leveling mechanism 54. For the depicted embodiment, a cluster or a sequential array of three low-pressure casting furnaces 22 are supported upon the leveling mechanisms 54 so that the top cover 40 of each of the three furnaces 22 is aligned. The leveling mechanisms 54 may be conventional machine tool leveling mechanisms 54. An installer or operator may employ a laser level in order to align the covers 40 of the furnaces 22.

By utilizing multiple furnaces 22, a very large sand mold 24 spanning all three furnaces 22 may be employed. The sand mold 24 is in fluid communication with the three furnaces 22. The controller 46 of the casting system 20 operates the three furnaces 22 to inject aluminum at three locations simultaneously with a computer-controlled filling and pressurization process. These locations are much further apart than is possible with multiple stalk tubes in a single furnace 22.

The furnaces 22 are arranged, from a plan view, in the shape of a right triangle with a center of each furnace 22 at a vertex of the triangle. For example, the first furnace 22 is spaced apart from a second furnace 56 at a first distance, or a first side of triangle. A third furnace 58 is spaced apart from the second furnace 56 in a direction perpendicular to the first furnace 22 to provide the right triangle. According to one embodiment, the first distance between the first furnace 22 and the second furnace 56 is greater than the second distance between second furnace 56 and the third furnace 58. Additionally, a third distance between the first furnace 22 and the third furnace 58 is greater than the first and second distances. Under one embodiment, an acute angle is formed between the first distance and the third distances; and an adjacent side of the triangle (first distance) is greater that an opposite side of the triangle (second distance). Under this arrangement, if a mold 60 is designed that requires only two furnaces 22, three different spacing options of the stalk tubes 38 is provided. Of course, any arrangement of two or more furnaces 22 may be utilized.

The casting system 20 enables castings to be made with a weight up to 3,000 pounds and a size up to twelve feet by twelve feet by eight feet. As a result, it is possible to cast a complete car chassis in a single component. By extending this concept further it is possible to cast parts of greater sizes and configurations.

FIGS. 1 and 4 illustrate a platform 62 provided generally flush with the furnace top covers 40 to provide a collective work surface across the furnaces 22, 56, 58. The platform 62 is supported upon the frame 50. FIG. 4 illustrates another platform 64 provided upon the frame 50 below the top covers 40 to provide a surface for operators to access the furnaces 22, 56, 58 and the molds 24, 28, 60.

While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. 

What is claimed is:
 1. A casting system comprising: at least two low-pressure casting furnaces, each adapted to be connected in fluid communication with a mold; and at least one controller in cooperation with the at least two low-pressure casting furnaces to collectively operate the low-pressure casting furnaces to cast a material into the mold.
 2. The casting system of claim 1 further comprising a plurality of stalk tubes, each stalk tube provided upon one of the at least two low-pressure casting furnaces to provide fluid communication from the one of the at least two low-pressure casting furnaces to the mold.
 3. The casting system of claim 2 wherein only one stalk tube is provided for each of the at least two low-pressure casting furnaces.
 4. The casting system of claim 1 further comprising a frame, wherein each of the at least two low-pressure casting furnaces is supported upon the frame.
 5. The casting system of claim 4 further comprising a plurality of leveling devices supported upon the frame, wherein each of the at least two low-pressure casting furnaces is supported upon one of the plurality of leveling devices.
 6. The casting system of claim 4 further comprising the mold supported upon the frame above the at least two low-pressure casting furnaces in fluid cooperation with each of the at least two low-pressure casting furnaces.
 7. The casting system of claim 1 wherein the at least two low-pressure casting furnaces further comprise at least three low-pressure casting furnaces; and wherein one pair of the at least three low-pressure casting furnaces is spaced apart a greater distance than another pair of the at least three low-pressure casting furnaces.
 8. The casting system of claim 1 wherein the at least two low-pressure casting furnaces further comprise at least three low-pressure casting furnaces that are arranged in a shape of a triangle with a center of each low-pressure casting furnace at a vertex of the triangle.
 9. The casting system of claim 8 wherein the shape of the triangle is a right triangle.
 10. The casting system of claim 9 wherein two sides of the triangle that are opposite and adjacent to an acute angle of the triangle are different lengths.
 11. The casting system of claim 1 further comprising the mold oriented upon the at least two low-pressure casting furnaces in fluid cooperation with each of the at least two low-pressure casting furnaces.
 12. The casting system of claim 11 wherein the mold further comprises a sand mold.
 13. A casting system comprising: a frame; a plurality of leveling devices supported upon the frame; and a plurality of low-pressure casting furnaces each supported upon one of the plurality of leveling devices, each adapted to be connected in fluid communication with a mold.
 14. A method for low-pressure casting comprising: providing two low-pressure casting furnaces in an adjacent series; providing a mold upon the low-pressure casting furnaces in fluid communication with each of the two low-pressure casting furnaces; and casting a single component in the mold from the two low-pressure casting furnaces.
 15. The method of claim 14 further comprising leveling the two low-pressure casting furnaces.
 16. The method of claim 14 further comprising casting the component from an aluminum material.
 17. The component formed from the method of claim
 14. 18. The component of claim 17 wherein the component weighs up to three thousand pounds.
 19. The component of claim 17 wherein the component occupies a volume of up to one thousand, one hundred and fifty-two cubic feet. 